Cooling Tower Efficiency Calculations

Cooling Tower Approach

The difference between the Cold Water Temperature (Cooling Tower Outlet)

And ambient Wet Bulb Temperature is called as Cooling Tower Approach.

Approach = Cold Water Temperature – Wet Bulb Temperature

Cooling Tower approach is the better indicator of the performance.

Cooling Tower Range

The difference between the Hot Water Temperature (Cooling Tower Inlet)
Temperature and Cold water (Cooling Tower Outlet) temperature is called Cooling
Tower Range.

Range = Hot Water Temperature – Cold Water Temperature

Cooling Tower Efficiency Calculation

The calculation of cooling tower efficiency involves the Range and approach of the
cooling Tower. Cooling tower efficiency is limited by the ambient wet bulb
temperature. In the ideal case, the cold water temperature will be equal to the wet-
bulb temperature. This is practically not possible to achieve. This requires very large
tower and results in huge evaporation and windage or drift loss resulting in a
practically not viable solution. In practice, the cooling tower efficiency will be in
between 70 to 75%.

Cooling Tower Efficiency =

(Hot Water Temperature – Cold water Temperature) x 100/

(Hot Water Temperature – Wet bulb temperature)

Or Simply

Cooling Tower Efficiency = Range/ (Range + Approach) x 100

In summer the ambient air wet bulb temperature raises when compared to winter
thus limiting the cooling tower efficiency.

Other Cooling Tower Calculations

This includes determination of cycle of concentration, Evaporation loss, Drift or
Windage Loss, Blow down water requirement makeup water requirement.

Cycle of Concentration
The cycle of concentration is a dimensionless number. It is a ratio between
parameter in Cooling Water to the parameter in Makeup water. It can be calculated
from any the following formulae.

COC= Silica in Cooling Water / Silica in Makeup Water

COC = Ca Hardness in Cooling Water/ Ca Hardness in Makeup water

COC = Conductivity of Cooling Water / Conductivity of Makeup water

The cycle of concentration normally varies from 3.0 to 7.0 depending on the Process
Design. It is advisable to keep the Cycle of concentration as high as possible to
reduce the makeup water requirement of the cooling tower. At the same time, the
higher cycle of concentration increases the dissolved solids concentration in
circulating cooling water which results in scaling and fouling of process heat transfer
equipment.
Draw off or Blowdown
As the cooling water circulates the cooling tower part of water evaporates thereby
increasing the total dissolved solids in the remaining water. To control the Cycle of
Concentration blow down is given. Blowdown is the function of Cycle of
concentration. Blowdown can be calculated from the formula:

B = E/ (COC-1)

B = Blow Down (m3/hr)

E = Evaporation Loss (m3/hr)

COC = Cycle of Concentration. Varies from 3.0 to 7.0 depending upon Manufactures
Guidelines

Evaporation Loss Calculation

Evaporation Loss in the cooling tower is calculated by the following empirical
equation.

E = 0.00085 x R x 1.8 x C

E = Evaporation Loss (m3/hr)

R= Range

C = Circulating Cooling Water (m3/hr)

(Reference: Perry’s Chemical Engineers Hand Book)

Alternatively, The Evaporation loss can be calculated from the heat balance across
the cooling tower. The amount of heat to be removed from Circulating water
according to Q = m Cp DT is C x Cp x R . The amount of heat removed by
evaporative cooling is Q = m x Hv is E x HV

On Equating these two, we get

E = C x R x C p / HV

E = Evaporation Loss in m3/hr

C= Cycle of Concentration
R= Range in °C

Cp = Specific Heat = 4.184 kJ / kg / °C

HV = Latent heat of vaporization = 2260 kJ / kg

Windage or Drift Loss Calculation

Drift loss of the cooling tower is normally provided by the cooling tower manufacturer
based on the Process design. If it is not available it may be assumed as

For Natural Draft Cooling Tower D = 0.3 to 1.0 * C /100

For Induced Draft Cooling Tower D = 0.1 to 0.3 * C /100

For Cooling Tower with Drift Eliminator D = 0.01* C /100

Cooling Tower Mass Balance – makeup water

Cooling tower mass balance gives an idea about make-up water requirement.
Cooling Tower Makeup has to substitute the water losses resulting from Evaporation,
Windage and Blowdown.

M=E+D+B
M = Make up water Requirement in m3/hr

B = Blow Down in m3/hr

E = Evaporation Loss in m3/hr

D = Drift Loss in m3/hr

 Cooling tower quiz

1. Approach of a Cooling Tower is

Difference between Cold water outlet temperature and Wet bulb temperature
Difference between Hot water Inlet temperature and Wet bulb temperature
Difference between Hot water Inlet temperature and Cold Water Outlet
temperature
Difference between Atmospheric temperature and Wet bulb temperature

2. Purpose of Louver is

To change the direction of Air inlet flow in the uniform manner

To prevent the water droplets splashing out of the tower
Both of the Above
None of the Above

3. Range of the Cooling tower is

Difference between Cold water outlet temperature and Wet bulb temperature
Difference between Hot water Inlet temperature and Wet bulb temperature
Difference between Hot water Inlet temperature and Cold Water Outlet
temperature
Difference between Atmospheric temperature and Wet bulb temperature

4. Purpose of Drift Eliminator is

To reduce the entrainment of Water droplets in Air

To prevent the water droplets splashing out of the tower
To provide the required surface area for heat transfer
All of these

5. The ratio of dissolved solids in circulating water to dissolved solids in makeup

water is called as

Evaporation ratio
Cycle of Concentration
L/G Ratio
 Efficiency

6. Purpose of blowdown is to

Remove the heat from Hot water

Maintain the Cold Water outlet temperature
Limit the increase in the concentration of solids in the water due to evaporation
To increase the efficiency

7. Cooling tower acceptance testing procedures are recommended by

CTI
API
ASME
ISO

8. Natural Draft or Hyperbolic towers have been used for

Large Capacity of water

Small Capacity of Water
High Efficiency
Low capital cost

9. Purpose of Cooling tower basin is

To serve as receptacle for Cooled water

To provide the storage capacity during Makeup water failure
To act as a reservoir for the cooling water pumps
All of these

10. The type of Cooling tower used in Power plants is

Hyperbolic Natural Draft Towers

Forced Draft Counter flow Towers
Induced Draft counter flow Towers
Dry Towers
11. A better Performance indicator of the Cooling tower is its

Dry bulb temperature

Approach
Range
Wet bulb Temperature

12. L / G ratio in cooling tower is the ratio between

Load and Temperature gradient

Length and girth
Air mass flow rate and water flow rate
Water flow rate and Air mass flow rate

13. Cooling Tower Efficiency =

Range/ (Range + Approach) x 100

Range/ Approach x 100
Approach/ Range x 100
Cold Water Temperature/ Hot water Temperature x 100

14. In practice, Common efficiency range achieved in the cooling tower is

98 to 100 %
90 to 95 %
95 to 98 %
70 to 75 %

15. The cycle of concentration normally varies from

0 to 3
3 to 7
10 to 15
15 to 100
16. To reduce the makeup water requirement of the cooling tower, Cycle of
Concentration to be kept
Very High
As High As Possible
Low
Very Low

17. Calculate the blow down loss of the Cooling tower from the following data. a)
Evaporation Loss is 500 m3/hr, b) Cycle of Concentration is 5
100 m3/hr
2500 m3/hr
125 m3/hr
Data Insufficient

18. Instrument used for Measuring Wet bulb Temperature is

Thermometer
Sling Psychrometer
Thermocouple
RTD

19. The temperature selection normally chosen for designing of cooling tower is
Average maximum wet bulb for winter months
Average maximum wet bulb for summer months
Average minimum wet bulb for winter months
Average minimum wet bulb for summer months

20. In a Daily Variation, Wet bulb temperature is maximum at

4 AM
4 PM
8 AM
8 PM

21. Which of the following is helpful in designing Cooling tower orientation?

Wind rose Diagram
Topographic map
Rain gauge recorder chart
Seismic Scale
22. The Purpose of fill is
To prevent the water droplets splashing out of the tower
To provide the required surface area for heat transfer between air and the water
To reduce the entrainment of Water droplets in Air
To change the direction of Air inlet flow in the uniform manner

23. The purpose of Torque tube is

To Transmit the power from the motor
To Give permanent alignment of the motor, driveshaft & gear reducer
To reduce the speed of the depending on the fan requirement
None of these

24. The purpose of Open disengaging stack is

To send the hot air from Cooling water out
To prevent the water droplets splashing out of the tower
To prevent tower from damage because of large gases in hot cooling water
None of these

25. Cooling towers operate on the principle of

Evaporative Cooling (Merkel Theory)
Henry's law
Stefan-Boltzmann Law
All of these

26. In which of the following fill Surface Area is more?

Splash Fill
Film Fill

27. FRP fan blades are used in Cooling tower applications because
It needs low starting torque
Easy handling and maintenance
Energy Efficient than Metal blades
All of these

28. Poor water distribution in a tower results in

Scale formation on fill
 Ice formation in cold climates
Wastage of Energy
All of these

29. Type of Level Measuring instrument used in Cooling Tower Basin is

Wet Leg DP Type
Gauge Glasses
Bubbler Type DP Cell
None of these

30. To prevent Scaling Silica level in Cooling water must be

Less than 500 ppm
Less than 150 ppm
Less than 1000 ppm
Less than 1500 ppm